Plasma cutter with disconnectable torch and work assemblies

ABSTRACT

Systems and methods relating to securing a torch assembly and a work lead assembly to a plasma cutting power supply are provided. The present disclosure relates to a system and method that allows the torch assembly and the work lead assembly to be readily replaced by the user since the power supply unit need not be opened or disassembled for removal. The present disclosure provides methods and systems for removably securing both the torch assembly and the work lead assembly to the plasma cutting power supply. In one embodiment, the torch assembly and the work lead assembly may be communicatively coupled to the plasma cutting power supply unit via a single cable and a single connector. The connection between the first connector and the first port may be of the quick disconnectable type. The connection between the second connector and the second port may be of the twist lock type, such as a dinse style connector.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Continuation Application of U.S. patentapplication Ser. No. 12/425,218, entitled “Plasma Cutter withDisconnectable Torch and Work Assemblies”, filed Apr. 16, 2009, which isa Non-Provisional Application of U.S. Provisional Patent Application No.61/052,045, entitled “Plasma Cutter with Disconnectable Torch and WorkCables”, filed May 9, 2008, both of which are herein incorporated byreference for all purposes.

BACKGROUND

The present disclosure relates generally to plasma cutting systems, andmore particularly, to methods and systems for removably connecting aplasma cutting torch and a work lead to a plasma cutting power supplyunit.

A plasma cutting system harnesses the energy in plasma (e.g., hightemperature ionized gas) to cut metal or other electrically conductivematerial. A plasma arc must be struck between components in the plasmacutting torch and the work piece. This process requires a voltage outputbetween the cutting torch and the workpiece. Accordingly, a power supplyunit coupled to a torch and a work lead is an integral part of anyplasma cutting system. Typical plasma cutting systems are configuredwith the torch and work lead cables permanently attached to the powersupply unit. However, when not in use, the user must manage lengthycables during transport or storage. Since one end of each cable of atraditional plasma cutting system is permanently attached to the powersupply unit, coiling is difficult because only one end of each cable canrotate freely.

Another difficulty associated with permanently connected cables is thatthe permanent attachment prohibits the storage of the cables inalternative locations. They must remain with the power supply. Further,the fixed ends of the cables generally extend outward, which leads to anawkward and inefficient storage shape.

BRIEF DESCRIPTION

The present disclosure is directed to systems and methods relating toremovably securing a torch assembly and a work lead assembly to a plasmacutting power supply. The present disclosure allows the torch assemblyand the work lead assembly to be easily removed and/or attached by theuser since the power supply unit need not be opened or disassembled forremoval. In particular, the present disclosure provides methods andsystems for removably securing both the torch assembly and the work leadassembly to the plasma cutting power supply. In one embodiment, thetorch assembly and the work lead assembly may be communicatively coupledto the plasma cutting power supply unit via a single cable and a singleconnector. In one embodiment, the connection or connections between thecables and the power supply may be of the quick connect type. In anotherembodiment, a first connection between a first cable and the powersupply may be of a twist lock type, (e.g. a dinse style connector), anda second connection between a second cable and the power supply may beof a quick disconnect type.

DRAWINGS

These and other features, aspects, and advantages of the presentdisclosure will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 illustrates an exemplary plasma cutting power supply with a torchassembly and a work lead assembly which are each removably attached tothe power supply unit in accordance with aspects of the presentdisclosure;

FIG. 2 illustrates an exemplary plasma cutting power supply with acombined torch and work lead assembly in accordance with aspects of thepresent disclosure;

FIG. 3 illustrates an exemplary plasma cutting power supply with a torchassembly and a work lead assembly unattached from the power supply unitin accordance with aspects of the present disclosure;

FIG. 4 illustrates an exemplary plasma cutting power supply with aprimary power supply cable removably attached to the power supply unitin accordance with aspects of the present disclosure;

FIG. 5 illustrates an exemplary plasma cutting power supply with acoiled torch assembly and a coiled work lead assembly hanging on a rackon the power supply unit in accordance with aspects of the presentdisclosure;

FIG. 6 illustrates an exemplary plasma cutting power supply with acoiled torch assembly and a coiled work lead assembly secured in a powersupply unit cover in accordance with aspects of the present disclosure;

FIG. 7 illustrates a user carrying a balanced load that includes a powersupply unit, a coiled torch assembly and a coiled work lead assembly inaccordance with aspects of the present disclosure; and

FIG. 8 illustrates an exemplary method of manufacturing the plasmacutting power supply system in accordance with aspects of the presentdisclosure.

DETAILED DESCRIPTION

FIG. 1 illustrates an exemplary plasma cutting power supply 10, whichfunctions to power and control a cutting operation in accordance withaspects of the present disclosure. An interface panel 12 on the frontside of the power supply unit 10 in the illustrated embodiment containsa control panel 14, through which a user may control the supply ofmaterials, such as power, gas flow, and so forth for a cuttingoperation, via switches 16, knobs 18, and so forth. Display 20 on thecontrol panel 14 provide the user with information regarding operationof the power supply unit 10. A torch assembly 22 and a work leadassembly 24 communicatively couple with the power supply unit 10. Thetorch assembly 22 includes a cutting torch 26 that is communicativelycoupled to a first port 28 in the power supply unit 10 via a first cable30 and a first connector 32 of the torch assembly 22. A second port 34facilitates coupling of the work lead assembly 24 with the power supplyunit 10. Specifically, the second port 34 allows a work lead 36 to becommunicatively coupled to the power supply 10 via a second cable 38 anda second connector 40. Portability of the unit 10 may be facilitated bya handle 42, which enables the user to easily grasp the power supplyunit 10 and move the power supply unit 10 to the location of aworkpiece. In some embodiments, the power supply unit 10 may becommunicatively coupled to additional system components, such as a wallpower outlet, a battery, engine-driven power sources, and so forth.

It is now recognized that there exists a need for techniques that canoffer improvements in storage and transportation efficiency of plasmacutting power supply units 10, thereby eliminating some of the technicaldifficulties associated with the storage and use of such units.Accordingly, in the embodiment illustrated in FIG. 1, the connectors 32,40 are readily attachable and/or detachable from the power supply unit10 by a user. In other words, both of the connectors 32, 40 areremovably attached to the first and second ports 28, 34. This is incontrast to traditional systems, which typically include a permanentattachment of the torch assembly 22 and/or work lead assembly 24 withthe power supply unit 10.

In the present disclosure, use of the term “permanently attached” mayindicate that features of a device are coupled together (e.g., duringmanufacturing) such that separate portions of the device must bedisassembled and/or broken to disconnect the coupled components.Additionally, in the present disclosure, the term “removably attached”or “readily detachable” may indicate that features of a device arecoupled together such that an ordinary user need not disassemble othercomponents of the device and/or break the device to uncouple thefeatures. For example, in accordance with present embodiments, a usermay decouple the torch assembly 22 from the power supply unit 10 withoutopening the power supply unit 10 or exerting extreme force. Further, insome embodiments, the torch assembly 22 and/or work lead assembly 24 maybe detached from the power supply unit 10 without disassembly of thepower supply unit 10 and without the use of tools.

The ability to removably attach both the torch assembly 22 and the worklead assembly 24 from the power supply unit 10 offers distinct benefits.For example, the torch assembly 22 and the work lead assembly 24 may beeasily coiled and stored separately from the power supply unit 10.Further, the torch assembly 22 and the work lead assembly 24 may beeasily replaced by the user since the power supply unit need not beopened or disassembled for disconnection. For instance, the user maychange the torch assembly 22 and the work lead assembly 24 when adifferent cable length would better suit the cutting operation.

FIG. 2 illustrates a single combined torch and work lead assembly 44communicatively coupled to the plasma cutting power supply unit 10. Inthis embodiment, the torch 26 and the work lead 36 may becommunicatively coupled to the power supply unit 10 via a single cable46 that branches off into two divisions at an extending end, wherein theextending end is the end of the cable 46 that connects to the torch 26and the work lead 36. At the end of the single cable 46 opposite theextending end, the single cable 46 couples with a single connector 48.The single cable 46 and the single connector 48 may provide gas,electricity, and a functional electric return path. The cutting torch 26and the work lead 36 may be utilized to perform cutting operations. Inthe illustrated embodiment, the work lead 36 includes a clamp 50. Duringoperation, the clamp 50 connects to a workpiece to close the circuitbetween the torch 26, the work piece, and the supply unit 10, and toensure proper current flow.

FIG. 3 illustrates the exemplary plasma cutting power supply 10 of FIG.1, wherein the torch assembly 22 and the work lead assembly 24 areunattached from the power supply 10. In one embodiment, the torch 26 maybe permanently attached to the first cable 30, which may permanentlyattach to the first connector 32. The first connector 32 may thenremovably attach to the first port 28 via a first secondary port 52 withan aperture 54, a second secondary port 56 and a third secondary port57. In the illustrated embodiment, the first secondary port 52 mayprovide gas, such as air, nitrogen, and so forth, for plasma generationto the torch assembly 22. The second secondary port 56 may provide theelectrical connections required by the torch 26, such as cutting power,pilot power, low voltage connections (e.g. cup sensor, trigger), and soforth. The third secondary port 57 may provide a securing mechanism. Inone embodiment, the connection between the first connector 32 and thefirst port 28 may be of the quick disconnectable type. It should benoted that in other embodiments, the various components of the torchassembly 22 may be removably attached with one another.

Much like the components of the torch assembly 22, the components of thework lead assembly 24 may be permanently coupled together and/orremovably attached. For example, in the illustrated embodiment, the worklead 36 may be permanently attached to the second cable 38, which maypermanently attach to the second connector 40. The second connector 40may then removably attach to the second port 34 to communicativelycouple the work lead assembly 24 to the power supply unit 10. In oneembodiment, the connection between the second connector 40 and thesecond port 34 may be of the twist lock type. In this embodiment, thesecond connector 40 may be a dinse style connector.

FIG. 4 illustrates the back panel 58 of the plasma cutting power supplyunit 10 in accordance with aspects of the present disclosure. In theillustrated embodiment, a primary power supply cable 60 that connectsthe power supply unit 10 to the primary source of power is removablyattached to a port 62 on the back panel 58 of the power supply unit 10through a connector 64. In this embodiment, the power supply unit 10 maybe compactly stored since the power supply cable 60 may be storedseparate from the unit 10. Additionally, the removably attached cable 60may be easily detached and replaced by the user. In other embodiments,the power supply cable 60 may be permanently attached to the powersupply unit 10.

FIG. 5 illustrates a plasma cutting power supply with both the torchassembly 22 and the work lead assembly 24 coiled and hanging on a racks66, 68 that are permanently secured or removably attached to a side ofthe power supply unit 10 in accordance with aspects of the presentdisclosure. In this embodiment, the torch assembly 22 and the work leadassembly 24 may be stored in the same location as the power supply unit10. In further embodiments, the racks 66, 68 may be removably secured sothe user may remove the racks 66, 68 when storage space for multiplepower supply units is limited. The racks 66, 68 may contain one or moreposts for storing one or more cables. In one embodiment, a single postmay be configured to hold more than one cable.

FIG. 6 illustrates a plasma cutting power supply 10 with the torchassembly 22 and the work lead assembly 24 coiled and secured in a powersupply unit cover 69 in accordance with aspects of the presentdisclosure. In this embodiment, the cover 69 may encase the power supplyunit 10 and hold the torch assembly 22 and the work lead assembly 24. Inother embodiments, the cover 69 may exclusively hold either the torchassembly 22 or the work lead assembly 24. Additionally, in otherembodiments, the cover 69 may hold the torch assembly 22 and the worklead assembly 24 in a single pocket. This embodiment may facilitateconvenient storage of the power supply unit 10, the torch assembly 22,and the work lead assembly 24 when the user would like to store thepower supply unit 10 in the location of the weld for future use.Additionally, this embodiment provides a compact way of transporting andstoring the power supply unit 10 when the user would like to store theunit 10 in a location distance from the location of the cut.

FIG. 7 illustrates a user 70 carrying a balanced load that includes thepower supply unit 10, the coiled torch assembly 22 and the coiled worklead assembly 24 in accordance with aspects of the present disclosure.In the illustrated embodiment, the user 70 may carry the power supplyunit 10 in one hand while carrying the torch assembly 22 and the worklead assembly 24 in the other hand to balance the load. Since thisembodiment facilitates transport of the power supply unit 10 when theuser 70 wishes to store or move the unit 10, it provides an advantageover typical systems that require the user 70 to carry the power supplyunit 10, the torch assembly 22, and the work lead assembly 24 in onehand.

FIG. 8 illustrates an exemplary method of manufacturing the plasmacutting power supply system 10 in accordance with aspects of the presentdisclosure. A manufacturing block 72 represents the manufacturing stageof the components of the plasma cutting system 10. A power supply unit10 base is manufactured, as represented by block 74. Additionally, aninterface panel 12 is manufactured, as represented by block 76.Subsequently, a first port 28 is provided in the interface panel 12, asrepresented by block 78, and a second port 34 is provided in theinterface panel 12, as represented by block 80. A torch lead assembly 22and a work lead assembly 24 are manufactured, as represented by blocks82 and 84. An assembly stage during which the manufactured componentsmay be connected follows the manufacturing stage 72. First, the base andthe interface panel 12 are permanently attached, as represented by block88. Subsequently, the torch assembly 22 and the work lead assembly 24may be removably attached to the power supply unit 10 if desired, asrepresented by blocks 90 and 92.

While only certain features of the present disclosure have beenillustrated and described herein, many modifications and changes willoccur to those skilled in the art. It is, therefore, to be understoodthat the appended claims are intended to cover all such modificationsand changes as fall within the true spirit of the present disclosure.

The invention claimed is:
 1. A plasma cutting system comprising: aplasma cutting power supply comprising a work lead port; and a work leadassembly comprising: a work lead; a quick disconnect work lead connectorconfigured to be removably inserted into the work lead port of theplasma cutting power supply, wherein the quick disconnect work leadconnector comprises a dinse style connector or a twist lock styleconnector and is configured to be removably attached to and removablydetached from the work lead port without the use of tools; and a worklead cable coupling the work lead with the quick disconnect work leadconnector.
 2. The system of claim 1, comprising a torch assemblycomprising: a torch; a torch connector configured to removably couplewith a gas port of the plasma cutting power supply and an electricalport of the plasma cutting power supply; and a torch cable coupling thetorch with the torch connector.
 3. The system of claim 2, wherein thetorch connector comprises a quick disconnect system.
 4. The system ofclaim 1, comprising a power supply cable, wherein the plasma cuttingpower supply comprises a power supply port, and the power supply cableis configured to removably couple with the power supply port of theplasma cutting power supply.
 5. The system of claim 1, wherein the quickdisconnect work lead connector comprises the dinse style connector. 6.The system of claim 1, wherein the quick disconnect work lead connectorcomprises the twist lock style connector.
 7. A plasma cutting systemcomprising: a plasma cutting power supply having an interface panelcomprising a gas port and a separate electrical port offset from eachother on the interface panel; a torch assembly comprising: a torch; atorch connector comprising a gas port connector configured to removablycouple with the gas port of the plasma cutting power supply and aseparate electrical port connector configured to removably couple withthe electrical port of the plasma cutting power supply; and a torchcable coupling the torch with the torch connector; and a work leadassembly comprising: a work lead; a quick disconnect work lead connectorcomprising a dinse style connector or a twist lock style connector,wherein the quick disconnect work lead connector is configured toremovably couple with a work lead port of the plasma cutting powersupply; and a work lead cable coupling the work lead with the work leadconnector.
 8. The system of claim 7, wherein the quick disconnect worklead connector comprises a dinse style connector.
 9. The system of claim7, wherein the quick disconnect work lead connector comprises a twistlock style connector.
 10. The system of claim 7, comprising a powersupply cable, wherein the plasma cutting power supply comprises a powersupply port, and the power supply cable is configured to removablycouple with the power supply port of the plasma cutting power supply.11. The system of claim 7, wherein the torch connector comprises a quickdisconnect system.
 12. A method of manufacturing a plasma cutting powersupply, comprising: providing a plasma cutting power supply having apanel on a side of the plasma cutting power supply; and providing a worklead port in the panel, wherein the work lead port is configured toremovably receive a quick disconnect connector of a work lead assemblysuch that the quick disconnect connector is readily detachable from thework lead port without the use of tools, wherein the quick disconnectconnector comprises a dinse style connector or a twist lock styleconnector.
 13. The method of claim 12, comprising: providing a gas portin the panel, wherein the gas port is configured to removably couplewith a torch assembly and to supply gas to the torch assembly; andproviding an electrical port in the panel, wherein the electrical portis configured to removably couple with the torch assembly and to supplypower to the torch assembly.
 14. The method of claim 13, comprisingremovably securing the torch assembly to the gas port and the electricalport.
 15. The method of claim 12, comprising removably securing thequick disconnect connector of the work lead assembly to the work leadport.
 16. The method of claim 12, comprising providing a primary powersupply cable that is configured to removably couple with a power supplyport of the plasma cutting power supply.
 17. The method of claim 12,wherein the quick disconnect connector of the work lead port comprisesthe dinse style connector.
 18. The method of claim 12, wherein the quickdisconnect connector of the work lead port comprises the twist lockstyle connector.